A minimum weight thin wall profile member is produced by selecting range values of cross section dimensions ratios for the thin wall profile member and various ratio values within the range values, and determining shape efficiency factor values Σ1, Σ2 . . . Σn based on the selected ratio values within the range values. Each shape efficiency factor value is determined using the expression Σ=Kf·Km, where Kf=(i2/F)2/5 is an overall stability factor, Km=K1/5/(b/δb)2/5 is a local stability factor, b, δb are the width and the thickness, respectively, of the main strip, i and F are the radius of gyration and the area of the cross-section, respectively, and K is the local stability stress coefficient. A maximum shape efficiency factor value Σmax is selected from the determined shape efficiency factor values, and the corresponding ratio values are used to produce the minimum weight thin wall profile member.